FURNITURE PRODUCTION MADE TO MEASURE: From the perfect surface through to innovative packaging technology
Laminating technology reacTec – the next generation
The starting point for development of the reacTec laminating method in association with Henkel and Nordson was the concept of taking the benefits of hot melt gluing without its drawbacks to create a new technique. The result is a new kind of hot melt glue using a system without open time which provides the ideal combination of process stability with almost exclusively positive technical characteristics.
| Compared to the three familiar gluing methods of urea, PVAC and hot-melt, the new reacTec laminating technology from HOMAG scores in terms of its low initial investment costs, its minimal space requirement, its scope for laminating surfaces and edges, its production reliability and emission-free glue joint. In addition, unlike water-based dispersion adhesives, this method avoids any penetration of water, helping to prevent swelling and so bringing about a substantial improvement in surface quality. |
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Another benefit: The new method eliminates the previously required drying time, and compared to EVA-based hot melt glues it also achieves greater thermal resistance and greater surface hardness. The new HOMAG reacTec technique presents the ideal combination of process stability and almost exclusively positive technical characteristics.
Using reacTec also helps reduce energy consumption by up to 50 % or over one million kWh taken over a year. Over the same period, carbon emissions are reduced by up to 700 tons, and users save up to 120,000 € in energy costs. Productivity is also increased and the proportion of scrap reduced. The overall cost savings achievable using the system can add up to as much as 400,000 €.
BÜTFERING sanding lines for industrial application
The SWT 900 and SWB 700 series from BÜTFERING are ideally suited for use in wide-ranging different industrial sanding applications such as lacquering or laminating lines. The SWT 900 machines are available in working widths of over 1350 mm for processing surfaces using up to six units – in freely configurable unit sequence. The SWB 700 series takes care of all workpiece underside processing requirements in sanding, lacquering or laminating lines. By combining and interlinking the two SWB 700 and SWT 900 series, workpieces can be processed on the upper and lower surface in a single pass without using additional handling equipment or intermediate conveying systems.
BÜTFERING offers a variety of equipment options such as servo-controlled feed gear, devices for online quality control or an automatic regulating system to correct thickness tolerances for both series. All these features open up scope for a high level of automation.
New FKW 100 surface laminating machine offers outstanding flexibility
FRIZ was on hand to show off its FKW 100 machine, a new version of its modular laminating line with an attractive entry level price tag. Its particular highlight: the combination glue application machine, which allows users to choose between PUR hotmelt or PVAc white adhesive. The concept of applying two different adhesives in a single machine has been ideally implemented by FRIZ with this new line. While the focus of the FKW 100 is firmly on the manufacture of top quality high gloss furniture elements, it also offers outstanding flexibility when it comes to door leaf processing (with and without honeycomb core) and the manufacture of kitchen work tops. By using a whole array of additional units from the modular optional range, the machine can be upgraded with maximum flexibility (see separate FRIZ press release).
HOMAG drives laser technology forward!
As the edge processing specialist, the HOMAG Group puts its considerable innovative weight behind the development of seamless solutions from edge improvement through gluing technology using all known types of edging materials to the patented HOMAG laserTec method. This innovative technology can now also be used for top-quality jointless edge banding also in processing centres (see separate HOMAG GmbH press release). HOMAG has succeeded in transposing the same quantum leap in zero-joint edge banding quality it achieved with straight edged workpieces over to the world of shaped components. Over recent months, no fewer than 60 throughfeed machines and several processing centres fitted with laserTec have been sold and an optimum degree of process reliability achieved. Irrespective of whether stationary or throughfeed technology is required – now almost any material can be simply, reliably processed to achieve the same optimum zero joint quality.
KBE 100 – edge precoating the easy way
Producers with ambitions to get involved in edge pre-coating will appreciate the benefits of the new HOMAG KBE 100. This machine ideally prepares edging material for subsequent processing using the laserTec process, coating conventional edges using a specially developed function layer. This allows even thin edging materials to be prepared for processing with laserTec. The machine is ideal for use in the entry level range for edging quantities of up to 2000 metres, as the availability of laser edges is not yet extensively guaranteed throughout the world market (see separate HOMAG GmbH press release).
HOMAG Group Engineering: THE specialists when it comes to complete plants!
Project engineering of complex production set-ups involving networked plants and systems is a special field of expertise for the HOMAG Group with an array of high-tech solutions using the latest machine and control technology. The solutions on offer cover the entire spectrum from series production through to plants producing batch sizes of just one.
The HOMAG Group works to a meticulously high standard of professionalism, and may claim to be the highest selling manufacturer in the plant business today. This is an area in which it clearly holds all the aces in terms of core competence: Supplying complete plants and cells calls for a totally professional approach, outstanding expertise and perfect performance from the engineering stage through to handover of the complete plant. It is down to the competence of all the Group companies and their high quality standard that the HOMAG Group is in a position to supply individually tailored solutions across the whole of the furniture and structural element industry.
PLANT COMPETENCE FROM A SINGLE MOULD
As supplier of the most comprehensive product portfolio offered anywhere in the marketplace, the HOMAG Group was exhibiting at the LIGNA with a complete batch size 1 plant, comprising everything from the innovative storage system and saw combination through to ultra-modern packaging technology. By producing on this high-tech solution from the HOMAG Group, users benefit from not one but three decisive benefits:
• 30 % greater output than comparable systems on the market
• 20 % less energy consumption
• 10 % lower space requirement
The batch size 1 plant was made up of the following high-tech components:
Scope for versatile configuration – the BARGSTEDT TLF 420
| The TLF 420 is the “big strong one” from BARGSTEDT. With laser control and rotating scissor, the cross beam of this high-volume storage system is capable of transporting a wide range of different panel formats with pinpoint precision, depositing them in transverse or longitudinal alignment – and all with an impressive output and application range. The robust machine construction underlying the system permits span widths of over 12 meters. The professional version of the storage system is supplied as standard and offers enormous capability. Fitted with a whole series of optimization modules, this storage system with its fully automatic control guarantees process reliability, process optimization and economy. |
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HOLZMA puts the saw in its place
HOLZMA will be presenting its patent-registered new “prescoring saw adjustment” as part of its 3 series. Working with the aid of what is known as an absolute measurement system, it stores the saw blade position for pinpoint repositioning accuracy after a saw blade change. The benefits of this technology include “vertical postforming” for books of parts. This technique allows the edges of complete books of parts to be scored up to a depth of 15 mm, providing an ideal supplementary equipment feature for cutting parts with veneered, paper or ABS edges.
flexTrim & powerTrim: Productivity increases by up to 50 %
The profile trimming unit powerTrim for rapid changeover between 3 profiles and the new profile scraper blade flexBlade, for instance, have set whole new milestones in terms of precision and time savings in trimming and profile processing, particularly for batch size one production. powerTrim provides a productivity increase of 50% compared to customary systems available in the field of flexible furniture production. It uses a multi trimming unit with servo adjusting motors for trimming work from above and below, a powerTrim profile trimming unit for rounding corners and the multi scraper blade with servo adjusting motors for workpiece finish processing. Using these 3 units in combination, flexible processing can be achieved with feed rates of 50 m/min and profile changing with a gap between workpieces of just 400 mm. powerTrim was used at the LIGNA on the K 350 series, and is a preferred option for use at the entry level for flexible batch size 1 production (see separate press release from HOMAG GmbH).
WEEKE: High-speed drilling technology in transverse throughfeed
A new drilling concept designed for maximum piece numbers processed in transverse throughfeed also made a big impression at the LIGNA. Faster and more effective than ever before and to the highest possible standard of quality. Complete vertical processing takes place from above and below in one section. The BST 800 offers fully automated drilling and resetting with a wide selection of drilling configurations coupled with up to 15% increases in output. Rounding off the spectrum of offered options is a dowelling unit – also equally suitable for small production runs.
LIGMATECH has cartons dancing
In the field of packaging technology, LIGMATECH has an answer to every conceivable requirement. Featured at the Ligna was a complete line for packaging furniture parts. New to the show was the cardboard folding machine VKF100, designed for small and medium batch sizes thanks to its extremely short resetting times. The featured automatic closing station VKV700 for cardboard box closure in also capable of high-speed resetting. In addition to this packaging line, LIGMATECH was also showing off its cardboard cutting machine VKS200/250, which was created in cooperation with the company Packsize: Always the right packaging, in the right quantity at the right time using simple logistics. The machine can optionally also be linked directly to the cardboard folding machine VKF100 (see separate press release from LIGMATECH).
MMR - Machine Monitoring & Reporting: Immediate fault detection
The HOMAG Group has plenty on offer when it comes to improving availability, with integrated production control technology playing a central role. Featured at the Ligna was an integrated process chain from planning through programming to production, focusing on continuous optimization of resource efficiency in the field of machine utilization. This is made possible by MMR (Machine Monitoring & Reporting), a software solution designed for the immediate detection and display of faults. These include both technical defects and also faults caused by operating errors or environmental factors. The intelligent acquisition logic integrated in this software solution additionally allows optimization potential to be registered and displayed in the form of graphic analyses.
STRUCTURAL ELEMENTS – a complete house from the HOMAG Group: Windows, doors, staircases, parquet and the timber frame house – the HOMAG Group has the ideal solution in every field
Window production: powerProfiler BMB 900 – a whole new class in window processing
One of the major highlights in the field of stationary technology this year is the new powerProfiler BMB900, a true multitalent that comes equipped with up to 432 tools. The challenge to produce "40 windows a day" was what prompted HOMAG to launch the development of automated processing centres capable of executing the whole range of tasks required for complete individual part processing in CNC precision – in other words the achievement of a degree of ready-to-assemble fitting accuracy requiring no finishing or reworking processes. This applies not only to standard window components. Also exceptionally small cross-sections under 50 mm and short lengths of below 170 mm for windows used in restoration projects , as well as for sash bars, large cross-sections up to 300 mm and long components up to 3,500 mm for upright and transom constructs can all be processed. The concept also offers scope for processing parts up to 6,000 mm by means of re-gripping and displacement. The spectrum even includes the production of round arch components and front door panels. For this, the powerBeam gripper table is fitted with consoles which are compatible for the entire highly flexible HOMAG clamp range (separate HOMAG GmbH press release).
Door production: All processing operations in a single clamping
New to TORWEGGE is a recently developed Optimat SBT 100 for the processing of door leaves. This compact, hardwearing door leaf processing machine is capable of performing the complete range of trimming and drilling operations needed for door locks. It also carries out every process required for hinges of any variety. Drilling boreholes for screw-in hinges on door leaves is also a standard assignment for the SBT 100. This machine is ideally suited for the production of small and medium-sized piece numbers. Depending on the equipment and technical requirements, this NC-controlled machine copes with between 120 and 150 door leaves per shift (see separate TORWEGGE press release).
FRIZ turns the glue application nozzle on its head
FRIZ took the LIGNA by storm with its new nozzle technology for profile wrapping and laminating machines. Integrated in the new wrapping line for processing door frames and architrave angles – comprising infeed magazine, profile wrapping machine PROFI PUM 310 and separating saw PUS 300 – this "bottom-up nozzle" offers users tremendous scope for versatility. To date, glue application from below on fixed length material (or veneer strips) was only possible using an open roller application unit. Using the new nozzle technology from FRIZ, glue is applied both to fixed length and coil material from below. This application technology also allows all glue types, in particular also PUR, to be applied from below (see separate FRIZ press release).
Staircase production: Gantry processing centre BMG 600
| The moving gantry processing centre BMG 600 follows in the footsteps of its predecessor, the enormously successful BMG 500. The BMG 600 is capable of coping with heavy-duty 5-axis processing operations up to 500 mm in height (including clamp). Its main fields of application are in vehicle and staircase construction, model building and shopfitting, as well as the processing of plastics and composite materials. |
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Use of the patented mineral material SORB TECH© helps increase tool service life by up to 20%. Instead of tread mats and photoelectric sensors, the patent registered safety system safeScan keeps a contact-free watch over the work area. The ideal add-on, in particular for 5-axis processing operations, is the software module collisionControl. This monitors processing online and helps prevent damage incurred as a result of collision due to programming errors (see separate HOMAG GmbH press release).
Flooring production: RANDOM LENGTH – multiple layer parquet in one go
Working together with HOMAG, TORWEGGE developed the double-end tenoner line RANDOM LENGTH for the crosswise processing of multi-layer parquet with “click” profile. All workpieces can have random lengths, as applies to the production of solid wood parquet. In this way, even smaller suppliers benefit from low-cost manufacture and optimum wood utilization when using random length material.
This machine is based on the 260 series and closes a still existing gap in the already wide HOMAG Group double-end tenoner range. The plant allows up to 100 workpieces to be processed per minute with up to 8 motor units – resulting in minimal resetting losses when changing dimensions due to the one-sided concept with integrated offset station.
WEINMANN: Combination wall system WEK 100
The WEK 100 for automatic production of wall and gable elements featured as part of the WEINMANN portfolio at the LIGNA. This compact combination multifunction bridge and beam processing centre is hardly bigger than a work table. Combining high performance with a minimal space requirement, this is the perfect solution for small to medium-sized timber frame construction firms. The automatic production of wall and gable elements can be performed on a single work station, is low in cost, requires significantly less space than two separate units and can also be operated by only a single employee. Companies producing smaller piece numbers can execute all types of panelization steps on the WEK 100. In larger companies, the WEK 100 is the perfect complement to a production line with insert table, butterfly turning table and multifunction bridge (see separate WEINMANN press release).